CN106825860B - Inverter type welder fault detection means - Google Patents

Inverter type welder fault detection means Download PDF

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Publication number
CN106825860B
CN106825860B CN201710043082.1A CN201710043082A CN106825860B CN 106825860 B CN106825860 B CN 106825860B CN 201710043082 A CN201710043082 A CN 201710043082A CN 106825860 B CN106825860 B CN 106825860B
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processing unit
central processing
voltage
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inverter type
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CN106825860A (en
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沈红东
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Nanjing Lishida Welding Technology Co Ltd
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Nanjing Lishida Welding Technology Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/095Monitoring or automatic control of welding parameters
    • B23K9/0956Monitoring or automatic control of welding parameters using sensing means, e.g. optical

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Inverter Devices (AREA)

Abstract

The invention discloses a kind of inverter type welder fault detection means, including central processing unit, adjustable voltage source, multiple voltage and current sample circuits, IGBT signal generating circuit, load selection circuit, load resistance and DC power supply load, the fault detection means applies the electric condition of an approximate duty state to inverter type welder to be detected, then the voltage and current value of inverter type welder is measured by multiple sample circuits, all kinds of voltage values that measurement obtains and current value are compared central processing unit with preset value or preset range, the specific fault type of welding machine is obtained by comparison result, the failure cause of welding machine finally, which is shown, by touch screen and provides corresponding maintenance suggests, greatly simplify the maintenance process of inverter type welder, reduce the requirement to the professional skill of maintenance personal.

Description

Inverter type welder fault detection means
Technical field
The present invention relates to field of welding devices more particularly to a kind of inverter type welder fault detection means.
Background technique
Inverter type welder is a kind of Arc Welding Power using inversion transformation technique, and the course of work is by three-phase or single-phase 50Hz power frequency A smoother direct current is obtained after AC rectification, filtering, the inverter circuit being made of IGBT pipe becomes the direct current The alternating current of 15~100kHz, after the decompression of intermediate frequency main transformer, rectifying and wave-filtering obtains stable direct current output welding electricity again The alternating current of frequency needed for stream or again inversion export.
Inverter type welder generally comprise rectifier bridge, filter capacitor, inverter circuit, high frequency transformer, fast-recovery commutation diode, The structures such as reactor, control circuit board and circuit board power supply.Wherein filter capacitor generally uses multiple electrolytic capacitors in parallel, These capacitors are often welded on one piece of circuit board, referred to as capacitor board.Inverter circuit part includes multiple discrete single tube IGBT devices Part, these IGBT pipe are often welded on one piece of circuit board, referred to as IGBT board.Protection signal circuit, the alarm signal electricity of welding machine Road, IGBT drive signal circuit etc. are typically integrated on one piece of circuit board, referred to as control circuit board.
Inverter type welder is substantially a kind of Switching Power Supply that output characteristics is very special, output power, and working environment is multiple It is miscellaneous, so the component of inverter type welder is easier damage, especially capacitor board, fast recovery diode, IGBT in use Plate and control circuit board.Therefore, in actual labour production, worker usually needs the maintenance problem in face of inverter type welder.Mesh Before, worker generally uses the failure of electric-resistivity method, voltage method, Shift Method and waveform determining method analysis inverter type welder.The inspection of these failures Survey method not only inefficiency, but also worker is required to have higher electricity knowledge and professional skill, the use of many inverter type welders Family itself is that do not have these conditions, it is necessary to provide after-sales maintenance service by inverter type welder manufacturer, this greatly increases The operating cost of producer.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of convenient and simple inverter type welder fault detection means.
In order to solve the above technical problems, the technical solution adopted by the present invention are as follows: a kind of inverter type welder fault detection means, packet It includes:
Central processing unit is equipped with inverter type welder fault detecting software in central processing unit;
Adjustable voltage source, adjustable voltage source are inverter type welder power supply, and the output voltage of adjustable voltage source is by central processing unit Control;
First current sampling circuit, the first current sampling circuit acquire the feedback current of adjustable voltage source and by collection results It is transferred to central processing unit;
Load resistance;
Load selection circuit, the load end that load resistance is connected to inverter type welder by loading selection circuit, central processing Device controls the load end whether load resistance accesses inverter type welder by load selection circuit;
Collection result is simultaneously transferred to by first voltage sample circuit, the voltage of first voltage sample circuit acquisition load resistance Central processing unit.
Further, fault detection means further include: second voltage sample circuit, the acquisition of second voltage sample circuit are inverse Become the output voltage of welding machine capacitor board and collection result is transferred to central processing unit.
Further, the fault detection means further include: DC power supply load, DC power supply load have current-limiting function, The load end that DC power supply load is connected to inverter type welder by loading selection circuit, central processing unit pass through load selection circuit Whether control DC power supply load accesses the load end of inverter type welder;
Second current sampling circuit, the second current sampling circuit acquire the feedback current of DC power supply load and tie acquisition Fruit is transferred to central processing unit.
Further, fault detection means further include: circuit occurs for IGBT driving signal, and electricity occurs for IGBT driving signal Central processing unit control is routed, the IGBT gate pole of circuit connection inverter type welder occurs for IGBT driving signal;
Third current sampling circuit, the drive signal current of third current sampling circuit acquisition IGBT gate pole output will simultaneously adopt Collection result is transferred to central processing unit.
Further, fault detection means further include: touch screen, touch screen are connect with central processing unit, and touch screen is used In human-computer interaction, worker inputs relevant parameter after connecting fault detection means, through touch screen, such as welding machine model, inspection Survey type etc.;Central processing unit is shown after obtaining corresponding failure conclusion, by corresponding fail result by touch screen Show, in the case of necessary, the software inhouse of detection device, which can also prestore some maintenances, suggests, central processing unit can be by event Barrier result and corresponding maintenance are suggested being shown together by touch screen.
Further, the fault detecting software includes:
Complete machine detection module, the output voltage that central processing unit controls adjustable voltage source gradually increase supreme electricity by low-voltage The specific value of pressure, the low-voltage and high voltage is determined that the load end of welding machine is by the concrete model of inverter type welder to be detected It is unloaded;Central processing unit compares the feedback current for the adjustable voltage source that the first current sampling circuit acquires with the first preset value It is right, if the feedback current of adjustable voltage source is more than the first preset value, determine inverter type welder failure, and fault type is capacitor Plate damage or IGBT board damage;If the feedback current of adjustable voltage source is no more than the first preset value, CPU passes through negative Selection circuit is carried by the load end of load resistance access welding machine, the load electricity that central processing unit acquires first voltage sample circuit The voltage of resistance is compared with the second preset value, if the voltage of load resistance determines lower than the second preset value and greater than zero Inverter type welder failure, fault type is that IGBT board is damaged or fast recovery diode damages, if the voltage of load resistance is not less than Second preset value then determines inverter type welder fault-free;
Capacitor board detection module, the output voltage that central processing unit controls adjustable voltage source are gradually increased supreme by low-voltage The specific value of voltage, the low-voltage and high voltage determines by the concrete model of inverter type welder to be detected, the load end of welding machine For zero load;The feedback current and third preset value ratio for the adjustable voltage source that central processing unit acquires the first current sampling circuit Right, central processing unit compares the capacitor board output voltage that second voltage sample circuit acquires with the 4th preset value, if adjustable The feedback current of voltage source is less than third preset value or capacitor board output voltage less than the 4th preset value, then determines inverter type welder Failure, fault type are capacitor board damage;
Fast recovery diode detection module, central processing unit disconnect adjustable voltage source, and central processing unit passes through load selection DC power supply is loaded the load end of access inverter type welder, the direct current that central processing unit acquires the second current sampling circuit by circuit The feedback current of power source loads is compared with the 5th preset value, presets if the feedback current of DC power supply load is greater than the 5th Value, then determine inverter type welder failure, and fault type is fast recovery diode short circuit;
IGBT board detection module, central processing unit disconnect adjustable voltage source, and the load end of welding machine is zero load;Central processing unit It controls IGBT driving signal and circuit generation driving signal, the IGBT door that central processing unit acquires third current sampling circuit occurs The drive signal current of pole output is compared with the 6th preset value, if the drive signal current of IGBT gate pole output is greater than the Six preset values, then determine inverter type welder failure, and fault type is the damage of IGBT gate pole;If the driving signal of IGBT gate pole output Electric current is not more than the 6th preset value, and load resistance is accessed the load of inverter type welder by load selection circuit by central processing unit End, the output voltage that central processing unit controls adjustable voltage source are gradually increased to high voltage, the low-voltage and height by low-voltage The specific value of voltage is determined that central processing unit acquires the first current sampling circuit by the concrete model of inverter type welder to be detected The feedback current of adjustable voltage source compared with the first preset range, central processing unit acquires first voltage sample circuit negative Carry resistance voltage compared with the second preset range, if the feedback current of adjustable voltage source not in the first preset range or The voltage of load resistance then determines inverter type welder failure not in the second preset range, and fault type is IGBT damage;
Control circuit board detection module, if the load resistance both end voltage measured in complete machine detection module is zero and electricity The testing result for holding plate detection module, fast recovery diode detection module and IGBT board detection module is normal, then determines inversion Welder fault, fault type are control circuit board damage.
The utility model has the advantages that inverter type welder fault detection means of the invention applies an approximate work to inverter type welder to be detected Make the electric condition of state, the voltage and current value of inverter type welder is then measured by multiple sample circuits, central processing unit will It measures obtained all kinds of voltage values and current value is compared with preset value or preset range, welding machine is obtained by comparison result Specific fault type, finally show the failure cause of welding machine by touch screen and provide corresponding maintenance and suggest, greatly letter The maintenance process for having changed inverter type welder reduces the requirement to the professional skill of maintenance personal.
Detailed description of the invention
Fig. 1 is 1 inverter type welder fault detection means working principle block diagram of embodiment.
Fig. 2 is 1 pressure-adjustable power circuit diagram of embodiment.
Fig. 3 is the circuit diagram of 1 first current sampling circuit of embodiment.
Fig. 4 is the circuit diagram that embodiment 1 loads selection circuit.
Fig. 5 is the circuit diagram of 1 second voltage sample circuit of embodiment.
Fig. 6 is the circuit diagram that circuit occurs for embodiment 1IGBT driving signal.
Fig. 7 is the circuit diagram of embodiment 1IGBT driving signal amplifying circuit.
Fig. 8 is the flow chart of 1 inverter type welder fault detecting software of embodiment.
Specific embodiment
Invention is further described in detail with reference to the accompanying drawings and detailed description.
Embodiment 1
As shown in Figure 1, the inverter type welder fault detection means of the present embodiment includes:
Central processing unit is equipped with inverter type welder fault detecting software, the present embodiment central processing unit in central processing unit Using TMS320F2812 as control chip, the Integrated Development Environment of CCS3.3 version is selected, using C language programming failure inspection Survey software;
Adjustable voltage source, adjustable voltage source are inverter type welder power supply, and the circuit diagram of adjustable voltage source is as shown in Fig. 2, adjustable Voltage source includes the power transformer with multichannel tap, and output voltage includes 0V, 30V, 90V, 150V, 220V and 380V, in Central processor controls corresponding relay to realize different voltage outputs;
First current sampling circuit, the first current sampling circuit acquire the feedback current of adjustable voltage source and by collection results It is transferred to central processing unit;The circuit diagram of first current sampling circuit is as shown in figure 3, SEN3 is Hall current sensor, electric current The current signal of sensor acquisition is by integrated circuit U11, U12 and other Resistor-Capacitor Units composition precise rectification circuit and difference Central processing unit is transferred to after processing of circuit;
Multichannel loading resistance;
Load selection circuit, the load end that load resistance is connected to inverter type welder by loading selection circuit, central processing Device controls the load end whether load resistance accesses inverter type welder by load selection circuit, and central processing unit passes through load selection Circuit control arbitrarily all the way load resistance access inverter type welder load end;Load selection circuit circuit diagram as shown in figure 4, its Middle XS3 connection multichannel loading resistance, the load end of XS4 connection inverter type welder, XS10 connection transformer;
Collection result is simultaneously transferred to by first voltage sample circuit, the voltage of first voltage sample circuit acquisition load resistance Central processing unit;
Second voltage sample circuit, second voltage sample circuit acquire the output voltage of inverter type welder capacitor board and will acquisitions As a result it is transferred to central processing unit, the circuit diagram of second voltage sample circuit is as shown in Figure 5;
DC power supply load, DC power supply load have current-limiting function, and DC power supply load is connected by load selection circuit It is connected to the load end of inverter type welder, central processing unit controls whether DC power supply load accesses inversion weldering by load selection circuit The load end of machine;As shown in figure 4, common group of bridge rectifier filter circuit of the compositions such as transformer and V25~V28 of XS10 connection It is loaded at DC power supply;
Second current sampling circuit, the second current sampling circuit acquire the feedback current of DC power supply load and tie acquisition Fruit is transferred to central processing unit;
Circuit occurs for IGBT driving signal, and IGBT driving signal occurs circuit and controlled by central processing unit, IGBT driving letter Number occur circuit connection inverter type welder IGBT gate pole;Fig. 6 and Fig. 7 is respectively that circuit and amplification electricity occur for IGBT driving signal Road, the U7 in Fig. 6 generate signal, metal-oxide-semiconductor Q5, Q6, Q10 and Q12 amplified signal in Fig. 7, T9 rfpa output signal;
Third current sampling circuit, the drive signal current of third current sampling circuit acquisition IGBT gate pole output will simultaneously adopt Collection result is transferred to central processing unit;
Touch screen, touch screen are connect with central processing unit, and touch screen is used for human-computer interaction, touch screen and central processing unit Communication uses RS-485, and communication protocol uses MODBUS RTU format, traffic rate 9600Bit/s.
The inverter type welder fault detecting software process of the present embodiment is as shown in figure 8, inspection software includes:
Complete machine detection module, the output voltage that central processing unit controls adjustable voltage source gradually increase supreme electricity by low-voltage The specific value of pressure, the low-voltage and high voltage is determined that the load end of welding machine is by the concrete model of inverter type welder to be detected It is unloaded;Central processing unit compares the feedback current for the adjustable voltage source that the first current sampling circuit acquires with the first preset value It is right, if the feedback current of adjustable voltage source is more than the first preset value, determine inverter type welder failure, and fault type is capacitor Plate damage or IGBT board damage;If the feedback current of adjustable voltage source is no more than the first preset value, CPU passes through negative Selection circuit is carried by the load end of load resistance access welding machine, the load electricity that central processing unit acquires first voltage sample circuit The voltage of resistance is compared with the second preset value, if the voltage of load resistance determines lower than the second preset value and greater than zero Inverter type welder failure, fault type is that IGBT board is damaged or fast recovery diode damages, if the voltage of load resistance is not less than Second preset value then determines inverter type welder fault-free;
Capacitor board detection module, the output voltage that central processing unit controls adjustable voltage source are gradually increased supreme by low-voltage The specific value of voltage, the low-voltage and high voltage determines by the concrete model of inverter type welder to be detected, the load end of welding machine For zero load;The feedback current and third preset value ratio for the adjustable voltage source that central processing unit acquires the first current sampling circuit Right, central processing unit compares the capacitor board output voltage that second voltage sample circuit acquires with the 4th preset value, if adjustable The feedback current of voltage source is less than third preset value or capacitor board output voltage less than the 4th preset value, then determines inverter type welder Failure, fault type are capacitor board damage;
Fast recovery diode detection module, central processing unit disconnect adjustable voltage source, and central processing unit passes through load selection DC power supply is loaded the load end of access inverter type welder, the direct current that central processing unit acquires the second current sampling circuit by circuit The feedback current of power source loads is compared with the 5th preset value, presets if the feedback current of DC power supply load is greater than the 5th Value, then determine inverter type welder failure, and fault type is fast recovery diode short circuit;
IGBT board detection module, central processing unit disconnect adjustable voltage source, and the load end of welding machine is zero load;Central processing unit It controls IGBT driving signal and circuit generation driving signal, the IGBT door that central processing unit acquires third current sampling circuit occurs The drive signal current of pole output is compared with the 6th preset value, if the drive signal current of IGBT gate pole output is greater than the Six preset values, then determine inverter type welder failure, and fault type is the damage of IGBT gate pole;If the driving signal of IGBT gate pole output Electric current is not more than the 6th preset value, and load resistance is accessed the load of inverter type welder by load selection circuit by central processing unit End, the output voltage that central processing unit controls adjustable voltage source are gradually increased to high voltage, the low-voltage and height by low-voltage The specific value of voltage is determined that central processing unit acquires the first current sampling circuit by the concrete model of inverter type welder to be detected The feedback current of adjustable voltage source compared with the first preset range, central processing unit acquires first voltage sample circuit negative Carry resistance voltage compared with the second preset range, if the feedback current of adjustable voltage source not in the first preset range or The voltage of load resistance then determines inverter type welder failure not in the second preset range, and fault type is IGBT damage;
Control circuit board detection module, if the load resistance both end voltage measured in complete machine detection module is zero and electricity The testing result for holding plate detection module, fast recovery diode detection module and IGBT board detection module is normal, then determines inversion Welder fault, fault type are control circuit board damage.
The welder fault detection device of the present embodiment be automatic equipment, user only need will test equipment with it is to be detected After welding machine connection, welding machine type is selected by touch screen, detection device is executed automatically according to program, until obtaining welding machine Until fault type or the trouble-free conclusion of welding machine, detection device is shown final testing result by touch screen. Correspondingly, the present embodiment can also prestore the maintenance suggestion of various different welder faults in a program, in display testing result Maintenance is provided together simultaneously to suggest.After the inverter type welder fault detection means for using the present embodiment, user is not having Also welding machine can be conveniently overhauled in the case where inverter type welder professional knowledge, and welder fault is avoided to influence labour production.
Although embodiments of the present invention are illustrated in specification, these embodiments are intended only as prompting, It should not limit protection scope of the present invention.It is equal that various omission, substitution, and alteration are carried out without departing from the spirit and scope of the present invention It should be included within the scope of the present invention.

Claims (2)

1. a kind of inverter type welder fault detection means, characterized by comprising:
Central processing unit is equipped with inverter type welder fault detecting software in central processing unit;
Adjustable voltage source, adjustable voltage source are inverter type welder power supply, and the output voltage of adjustable voltage source is controlled by central processing unit;
First current sampling circuit, the first current sampling circuit acquire the feedback current of adjustable voltage source and transmit collection result To central processing unit;
Load resistance;
Selection circuit, the load end that load resistance is connected to inverter type welder by loading selection circuit are loaded, central processing unit leads to Whether overload selection circuit control load resistance accesses the load end of inverter type welder;
Collection result is simultaneously transferred to center by first voltage sample circuit, the voltage of first voltage sample circuit acquisition load resistance Processor;
Second voltage sample circuit, second voltage sample circuit acquire the output voltage of inverter type welder capacitor board and by collection results It is transferred to central processing unit;
DC power supply load, DC power supply load have current-limiting function, and DC power supply load is connected to by loading selection circuit The load end of inverter type welder, central processing unit control whether DC power supply load accesses inverter type welder by load selection circuit Load end;
Second current sampling circuit, the feedback current of the second current sampling circuit acquisition DC power supply load simultaneously pass collection result It is handed to central processing unit;
Circuit occurs for IGBT driving signal, and IGBT driving signal occurs circuit and controlled by central processing unit, IGBT driving signal hair The IGBT gate pole of raw circuit connection inverter type welder;
Third current sampling circuit, third current sampling circuit acquire the drive signal current of IGBT gate pole output and tie acquisition Fruit is transferred to central processing unit;
The fault detecting software includes:
Complete machine detection module, the output voltage that central processing unit controls adjustable voltage source are gradually increased to high voltage by low-voltage, The low-voltage and the specific value of high voltage are determined that the load end of welding machine is sky by the concrete model of inverter type welder to be detected It carries;Central processing unit compares the feedback current for the adjustable voltage source that the first current sampling circuit acquires with the first preset value It is right, if the feedback current of adjustable voltage source is more than the first preset value, determine inverter type welder failure, and fault type is capacitor Plate damage or IGBT board damage;If the feedback current of adjustable voltage source is no more than the first preset value, CPU passes through negative Selection circuit is carried by the load end of load resistance access welding machine, the load electricity that central processing unit acquires first voltage sample circuit The voltage of resistance is compared with the second preset value, if the voltage of load resistance determines lower than the second preset value and greater than zero Inverter type welder failure, fault type is that IGBT board is damaged or fast recovery diode damages, if the voltage of load resistance is not less than Second preset value then determines inverter type welder fault-free;
Capacitor board detection module, the output voltage that central processing unit controls adjustable voltage source gradually increase supreme electricity by low-voltage The specific value of pressure, the low-voltage and high voltage is determined that the load end of welding machine is by the concrete model of inverter type welder to be detected It is unloaded;Central processing unit compares the feedback current for the adjustable voltage source that the first current sampling circuit acquires with third preset value, Central processing unit compares the capacitor board output voltage that second voltage sample circuit acquires with the 4th preset value, if adjustable piezoelectricity The feedback current in source is less than third preset value or capacitor board output voltage less than the 4th preset value, then determines inverter type welder event Barrier, fault type are capacitor board damage;
Fast recovery diode detection module, central processing unit disconnect adjustable voltage source, and central processing unit passes through load selection circuit DC power supply is loaded to the load end of access inverter type welder, the DC power supply that central processing unit acquires the second current sampling circuit The feedback current of load is compared with the 5th preset value, if the feedback current of DC power supply load is greater than the 5th preset value, Then determine inverter type welder failure, fault type is fast recovery diode short circuit;
IGBT board detection module, central processing unit disconnect adjustable voltage source, and the load end of welding machine is zero load;Central processing unit control IGBT driving signal occurs circuit and generates driving signal, and the IGBT gate pole that central processing unit acquires third current sampling circuit is defeated Drive signal current out is compared with the 6th preset value, if the drive signal current of IGBT gate pole output is greater than the 6th in advance If value, then inverter type welder failure is determined, fault type is the damage of IGBT gate pole;If the drive signal current of IGBT gate pole output No more than the 6th preset value, load resistance is accessed the load end of inverter type welder by load selection circuit by central processing unit, in Central processor controls the output voltage of adjustable voltage source and is gradually increased to high voltage by low-voltage, the low-voltage and high voltage Specific value is determined that central processing unit acquires the first current sampling circuit adjustable by the concrete model of inverter type welder to be detected The feedback current of voltage source is compared with the first preset range, the load resistance that central processing unit acquires first voltage sample circuit Voltage compared with the second preset range, if the feedback current of adjustable voltage source not in the first preset range or load electricity The voltage of resistance then determines inverter type welder failure not in the second preset range, and fault type is IGBT damage;
Control circuit board detection module, if the load resistance both end voltage measured in complete machine detection module is zero and capacitor board The testing result of detection module, fast recovery diode detection module and IGBT board detection module is normal, then determines inverter type welder Failure, fault type are control circuit board damage.
2. inverter type welder fault detection means according to claim 1, it is characterised in that further include:
Touch screen, touch screen are connect with central processing unit, and touch screen is used for human-computer interaction.
CN201710043082.1A 2017-01-19 2017-01-19 Inverter type welder fault detection means Active CN106825860B (en)

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Publication number Priority date Publication date Assignee Title
WO2019021768A1 (en) * 2017-07-25 2019-01-31 パナソニックIpマネジメント株式会社 Arc welding machine
CN110625220B (en) * 2018-06-22 2023-06-23 上海文顺电器有限公司 Intelligent inspection and debugging device and method for electric welding machine

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CN205430082U (en) * 2016-03-23 2016-08-03 许昌学院 Contravariant welding machine electrical power generating system with power factor correction function

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